Tile overlay system and method

ABSTRACT

A tile overlay system and method for covering a defined base surface area with tiles of a predetermined size for placement in a predetermined pattern that forms a space between each tile. The tiles are placed according to a grid defined on the base surface area to form the predetermined pattern. Prior to placement of the tiles, a transparent liquid adhesive is applied over the base surface area which allows the grid to appear through the layer of liquid adhesive. While the adhesive is in the liquid form, a granular filler material is broadcasted in the space between the tiles. The granular filler material is absorbed into the liquid adhesive to integrally bond therewith wherein the adhesive layer cures after the placement of the tiles, and after placement of the granular filler material thereby bonding the tiles and the granular filler material to the base surface area. Subsequently, a continuous transparent top coat is applied in liquid form over the tiles and granular filler material to form a continuous top surface that seals the tiles and the granular filler material.

This application claims the benefit of U.S. Provisional Application No.60/498,883 filed Aug. 29, 2003.

BACKGROUND

This invention relates generally to coverings and overlays forhorizontal surfaces including countertops and floors, and moreparticularly to tile overlay systems for such base surfaces.

Tile overlay systems have long been provided as a top covering for basesurfaces such as floors and countertops. Accordingly, a wide range ofcoverings and overlays for countertops and floors are available. Manysuch coverings include individual “stone” tiles bonded to a base surfaceand spaced in a way to allow a cement based grout filler material tofill the uneven grooves between the individual tiles. Typically, thistype of installation covers the base surface to the extent that theinstaller cannot see the base surface through the bonding material.Accordingly, the tiles have to be positioned by mechanical spacers orthe like. In addition, the grout cannot be placed until the mortarbonding material sufficiently sets-up so that the installer can removethe mechanical spacers and work on the set tiles.

Examples of some early systems include U.S. Pat. No. 4,311,464 issued inJanuary 1982 showing tiles cut and arranged according to a grid providedon a transparent sheet. Although a grid is employed, floor tiles in thissystem are laid in a bed of mortar, and require mechanical spacers forproper positioning.

Likewise, U.S. Pat. No. 4,659,409 issued in 1987 illustrating a methodfor preparing a floor covering by using a translucent template tosimulate, on a reduced scale, the over-lay material required to fill afloor space. In the final steps, however, the tiles have to bepositioned and grouted in a traditional manner.

Additionally, U.S. Pat. No. 4,744,194 issued in 1988 showing a method oflaying tile like members on a floor by employing interconnectedframework to space the floor tiles in a bed of mortar. Also, U.S. Pat.No. 5,000,890 issued in March 1991 disclosing a conventional method forresetting separated tiles using grout bonding material.

Alternatively, U.S. Pat. No. 5,271,200 issued in 1993 showing a tiledisplay system comprising a metallic sub-flooring provided for placementof magnetic means to secure the tile to the sub-floor. This system,however, is complicated and does not provide permanent placement of thetiles.

Later, in April 1993, U.S. Pat. No. 5,201,130 issued disclosing a tiletemplate having opposed arms at right angles to form a mechanicalspacer. Like most of the above noted devices, the '130 patent employstraditional materials such as mortar to set the tiles.

U.S. Pat. No. 5,806,270 issued in 1998 to showing a method of floorconstruction with a grid system utilizing interlocking grid members,cushion pads and grout strip members to form a floor. This constructionrequires many steps, and also employs grout material for setting thetiles.

In 1999, U.S. Pat. No. 5,930,974 issued showing a platform and supportto permit an installer to walk over freshly tiled areas. Like theinstallations noted above, spacers and common grout materials are usedto position and set the tiles. In addition, U.S. Patent applicationpublished in September 2002 discloses an apparatus for “mechanically”spacing tiles which are laid on a bed of grout in a traditional manner.

As noted above, most floor systems that employ individual tile membersare installed in a traditional manner where tiles are spaced accordingto mechanical spacers over a bed of mortar that obscures the installer'sview of the base surface, and wherein a cement based grout is finallyapplied to fill in the spaces between the tiles.

Because such arrangements require the step of placing and removingmechanical spacers to properly place the individual tiles, theinstallation is costly and time consuming.

Accordingly, an improved tile system is needed that hastens the preciseinstallation of tiles and filler material disposed between the same toform a durable integral top covering surface.

SUMMARY

One object of the invention is to reduce the time required to install atile overlay floor system.

A second object is to reduce the cost of installing a tile floor system.

Another object is to improve the durability of a tile overlay floorsystem.

Yet another object is to provide a tile floor system installed bymethods that an installer can quickly learn.

A further object is to enable the installer to lay the tiles in properposition, and then quickly thereafter fill the gaps between the tileswith a filler material.

Still another object is to provide a tile overlay system that sets-up toform an integral, continuous gap-free surface.

The invention is a tile overlay system for covering a defined basesurface area. Typically, the tile overlay system comprises a pluralityof tiles having a predetermined size for placement in a predeterminedpattern that forms a space between each tile. In the present invention,the tiles are flexible, however rigid tiles could be substituted withequally satisfactory results.

In order to accurately place the tiles, a grid is defined on the basesurface area for positioning the tiles over the same to form thepredetermined pattern. Further, a transparent liquid adhesive is appliedover the base surface area to allow the grid to appear through the layerof liquid adhesive. In this way, the installer can place the tiles,according to the grid, over the adhesive. In addition, while theadhesive is in the liquid form, a granular dry filler material isbroadcasted and spread, over and in the space between the tiles. Becausethe granular filler material is dry, the same is absorbed into theliquid adhesive to integrally bond therewith, wherein the adhesive layercures after the placement of the tiles, and after placement of thegranular filler material thereby bonding the tiles and the granularfiller material to the base surface area.

Finally, a continuous transparent top coat is applied in liquid formover the tiles and granular filler material to form a continuous topsurface that seals the tiles and the granular filler material.

The foregoing and other objects, features, and advantages of thisinvention will become more readily apparent from the following detaileddescription of a preferred embodiment which proceeds with reference tothe accompanying drawings, wherein the preferred embodiment of theinvention is shown and described, simply by way of illustration of thebest mode contemplated of carrying out the invention. As will berealized, the invention is capable of other and different embodiments,and its several details are capable of modifications in various obviousrespects, all without departing from the invention. Accordingly, thedrawings and description are to be regarded as illustrative in nature,and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a finished tile overlay system withportions broken away to illustrate the corner area with adjacent wallsextending upward from the base surface area that supports a tile overlaysystem.

FIG. 2 is a partial sectional view taken along 2-2 illustrating therelationship of the primary components of a finished tile overlay systemin accordance with the present invention.

FIG. 3 is the first illustration in the series of FIGS. 3 through 8which illustrate in sequence the steps required to install a tileoverlay system in accordance with the present invention, wherein FIG. 3is a perspective view with portions broken away to illustrate the cornerarea of a base sub-floor with adjacent walls extending upward therefrom,wherein the base sub-floor is ready to receive the tile overlay system.

FIG. 4 is a plan view of a placement grid design scribed or drawn on thebase sub-floor wherein the grid is defined by sets of crossing,intersecting parallel lines.

FIG. 5 is perspective view with portions broken away to illustrate thecorner area of a base sub-floor having a placement grid design, whereinthe sub-floor is covered with a substantially transparent, clearadhesive prior to receiving individual tiles.

FIG. 6 is perspective view with portions broken away to illustrate thecorner area of a base sub-floor having a placement grid design, whereinafter the sub-floor is covered with a clear adhesive, individual tilesare placed according to the placement grid.

FIG. 7 is perspective view with portions broken away to illustrategranular filler material being broadcast over the set tiles so that thefiller fills the spaces and/or gaps between the individual tiles andflows into the wet adhesive.

FIG. 8 is perspective view with portions broken away to illustrate toploose filler, not absorbed into the wet adhesive, being removed andbrushed off the tiles, followed with a top coat applied over the entiretiled area to form a continuous integral finish and top surface readyfor its intended use.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

The invention is a tile overlay system 20 and method for covering adefined base surface area 22. Typically, the tile overlay system 20comprises a plurality of tiles 24 having a predetermined size forplacement in a predetermined pattern that forms a space 26, or a gapbetween each tile 24. In the present invention, the tiles 24 areflexible, however rigid tiles could be substituted with equallysatisfactory results. Moreover, it should be noted that for the sake ofsimplicity the following assumes that each individual tile 24 issubstantially alike and defines a tile surface 30. However eachindividual tile 24 could be dissimilar in that it could incorporate adistinctive tile surface 30 resulting from the way the tile is formed.For example, each tile 24 could have a surface image which could includehand painted art, photos, or a distinctive troweled texture (notillustrated). Typically, the tiles 24 are constructed as a compositecomprising epoxy as a base.

In order to accurately place the tiles 24, a grid 34 is defined on the(sub-floor) base surface area 22 for positioning the tiles 24 over thesame to form the predetermined pattern 36. Typically, the base surfacearea 22 lies within the boundary of walls 37.

Further, an adhesive 38 is applied in transparent liquid form over thebase surface area 22 to allow the grid 34 to appear through the liquidadhesive 38. In this way, the installer can place the tiles 24,according to the grid 34, over the adhesive 38. In addition, while theadhesive 38 is in the liquid form, a dry granular filler material 40 isbroadcasted in the space 26 between the tiles 24. Because the granularfiller material 40 is typically dry, the same is absorbed into theliquid adhesive 38 to integrally bond therewith, wherein the adhesive 38cures after the placement of the tiles 24, and after placement of thegranular filler material 40 thereby bonding the tiles 24 and thegranular filler material 40 to the base surface area 22.

In a final application, a continuous transparent top coat 42 is appliedin liquid form over the tiles 24 and granular filler material 40 to forma continuous top surface 44 that seals the tiles 24 and the granularfiller material 40.

Considering now in more detail, a tile overlay system 20 in accordancewith the present invention, typically the individual tiles 24 areconstructed to form a flexible material. For this purpose, a compositemixture of epoxy in combination with a filler is suitable. Importantly,there are many types of epoxies and fillers presently available andsuitable for manufacturing tiles according to the present invention.Typically, the tiles 24 are formed to be approximately ⅛^(th) inch inthickness, and can have a tile surface 30 shaped with a trowel as theepoxy mixture starts to harden or cure. Further, in the hardeningprocess, the tile could be textured by adding a sand or the like, andskip troweled to make the tile surface 30 take on the appearance of realstone. Accordingly, the tile surface 30 can have raised areas, as wellas low areas which enhance the tile surface 30 to look like real stone(not illustrated).

Because an adhesive 38 is employed to bond the tiles 24 to a basesurface area 22, a fabric backing 48 can be applied to the bottom ofeach tile 30 while the same is in the formation process. In this way,the fabric backing 48 increases the strength of the bonding between thetile 30 and, as illustrated in FIGS. 1 through 8, a base sub-floor 46which defines the base surface area 22. Although such fabric backing 48could consist of almost any commercially available backing material, afabric backing 48 made from polyester or polypropylene is employed inthe present invention.

Turning now to FIG. 4, a grid 34 is laid out on the base sub-floor 46prior to laying the tile 24. In the present system, the grid 34comprises groups or sets of parallel lines 50 disposed at right anglesand drawn onto the sub-floor with chalk, or the like. Parallel lines 50are employed to define the predetermined tile laying pattern or grid 34,and to define the space 26 between the individual tiles 24.Specifically, the installer places the tiles 24 so that each edge 54thereof align with one of the parallel lines 50 as illustrated in FIG.4. Unlike conventional tile installations, the above noted installationprocedure requires no mechanical spacers to properly place the tiles 24.This not only speeds installation by making it easier to lay tiles, butreduces the cost and time of installation.

Directing attention to FIG. 5, an adhesive 38 is placed to the basesurface area 22 defined by the base sub-floor 46 prior to laying thetiles 24, and after drawing the grid 34. In the present invention, theadhesive 38 is clear, or nearly clear so that the installer can see thegrid 34 through the adhesive 38 to lay the tiles 24 as illustrated inFIG. 6. An adhesive 38 for this purpose could consist of a clear epoxymixed from two parts, i.e., an epoxy base mixed with a hardener. Aftermixing the adhesive 38, the same could be applied by troweling the sameover the base sub-floor 46. Because the adhesive 38 is in a liquid orsemi-liquid state, it is self-leveling, thus creating an even thicknesscoating over which the tiles 24 are laid.

As noted above, after placing the tiles 24 over the adhesive 38,according to the grid 34, a granular filler material 40 is broadcastover the tiles 24 into the space 26 between the tiles 24 as illustratedin FIG. 7. Typically, a dry colored quartz 56 is employed. Because thequartz is dry, it mixes quickly with the liquid adhesive 38 and becomesembedded therein as the adhesive hardens. Importantly, this constructioncreates a monolithic like floor covering that is very strong andresistant to deterioration and wear.

Following this, and after the adhesive 38 sets up and hardens, theremaining granular filler material 40 is removed from the tiles 24.Turning now to FIG. 8, a top coat 42, is spread in liquid form to coverthe entire floor surface to provide a continuous, hard, sealed coatingthat further creates a wear resistant surface. One coating provided forthis purpose is a two-part type polyurethane mixed to cure and form ahard surface. Although, a polyurethane is employed in the presentinvention, many other coatings are available that could be applied toform a top coat as described above.

In addition to the above, variations of the above process can be used.For example, the material used to fill the space 26 between the tiles 24could be any color dry granular material which can be absorbed into theadhesive 38. In this way, the installer could hand paint the hardenedfiller material to have the look of cement grout, prior to applying thetop coat 42.

Having illustrated and described the principles of my invention in apreferred embodiment thereof, it should be readily apparent to thoseskilled in the art that the invention can be modified in arrangement anddetail without departing from such principles. I claim all modificationscoming within the spirit and scope of the accompanying claims.

1. A method for constructing a tile overlay system for covering a base surface area, the method comprising the steps: providing a plurality of tiles having a predetermined size for placement in a predetermined pattern that forms a space between each tile; marking the base surface area to define a grid thereon for positioning the tiles in the predetermined pattern; placing a transparent liquid adhesive over the base surface area to allow the grid to appear through the liquid adhesive layer thereby enabling placement of the tiles according to the grid; placing the tiles according to the grid which can be viewed through the transparent adhesive, wherein the adhesive layer cures after the placement of the tiles in the predetermined pattern to bond the tiles to the base surface area; broadcasting a granular filler material in the space between the tiles while the adhesive is in the liquid form so that the granular filler material is absorbed into the liquid adhesive to integrally bond therewith; and applying a continuous transparent top coat in liquid form over the tiles and granular filler material to form a continuous top surface that seals the tiles and the granular filler material.
 2. A method for constructing a tile overlay system as recited in claim 1 further comprising the step: removing the excess granular filler material prior to applying the top coat.
 3. A method for constructing a tile overlay system as recited in claim 1 further comprising the step: preparing a tile surface on at least one tile so that the prepared tile surface can be seen through the transparent top coat.
 4. A method for constructing a tile overlay system as recited in claim 3 wherein the tile surface is prepared by hand painting the tile surface to exhibit a distinct appearance.
 5. A method for constructing a tile overlay system as recited in claim 3 wherein the tile surface is prepared by fixing a photograph to the tile surface to exhibit a distinct appearance.
 6. A method for constructing a tile overlay system as recited in claim 1 further comprising the step: marking the base surface area to define a grid thereon defined by a plurality of intersecting, crossing lines provided to assist in positioning the tiles in the predetermined pattern.
 7. A method for constructing a tile overlay system as recited in claim 1 further comprising the step: marking the base surface area to define a grid thereon defined by a plurality of intersecting, crossing sets of parallel lines provided to assist in positioning the tiles in the predetermined pattern.
 8. A tile overlay system for covering a surface area, the tile overlay system comprising: a plurality of tiles having a predetermined size for placement in a predetermined pattern that forms a space between each tile; a grid defined on the surface area for positioning the tiles over the surface area to form the predetermined pattern; an adhesive layer applied in transparent liquid form over the surface area to allow the grid to appear through the liquid adhesive layer to enable placement of the tiles according to the grid, wherein the adhesive layer cures after the placement of the tiles in the predetermined pattern to bond the tiles to the surface area; granular filler material placed. in the space between the tiles while the adhesive is in the liquid form so that the filler material is absorbed into the liquid adhesive to integrally bond therewith; and a continuous transparent top coat applied in liquid form over the tiles and granular filler material to form a continuous top surface that seals the tiles and the granular filler material.
 9. A tile overlay system as recited in claim 8 further comprising: a tile surface prepared on at least one tile so that the prepared tile surface can be seen through the transparent top coat.
 10. A tile overlay system as recited in claim 9 wherein the tile surface is prepared by hand painting the tile surface to exhibit a distinct appearance.
 11. A tile overlay system as recited in claim 9 wherein the tile surface is prepared by fixing a photograph to the tile surface to exhibit a distinct appearance.
 12. A tile overlay system as recited in claim 8 wherein the grid is defined by a plurality of intersecting, crossing lines provided to assist in positioning the tiles in the predetermined pattern.
 13. A tile overlay system as recited in claim 8 wherein, the grid is defined by a plurality of intersecting, crossing sets of parallel lines provided to assist in positioning the tiles in the predetermined pattern.
 14. A tile overlay system as recited in claim 8 wherein the tiles comprise a fabric backing disposed for contact with the liquid adhesive.
 15. A method for constructing a tile overlay system for covering a base surface area, the method comprising the steps: providing a plurality of tiles having a predetermined size for placement in a predetermined pattern that forms a space between each tile; marking the base surface area to define a grid thereon for positioning the tiles in the predetermined pattern wherein the grid is defined by a plurality of intersecting, crossing sets of parallel lines provided to assist in positioning the tiles in the predetermined pattern; placing a transparent liquid adhesive over the base surface area to allow the grid to appear through the liquid adhesive layer thereby enabling placement of the tiles according to the grid; placing the tiles according to the grid which can be viewed through the transparent adhesive, wherein the adhesive layer cures after the placement of the tiles in the predetermined pattern to bond the tiles to the base surface area; broadcasting a granular filler material in the space between the tiles while the adhesive is in the liquid form so that the granular filler material is absorbed into the liquid adhesive to integrally bond therewith; removing the excess granular filler material prior to applying the top coat; and applying a continuous transparent top coat in liquid form over the tiles and granular filler material to form a continuous top surface that seals the tiles and the granular filler material.
 16. A method for constructing a tile overlay system as recited in claim 15 further comprising the step: preparing a tile surface on at least one tile so that the prepared tile surface can be seen through the transparent top coat.
 17. A method for constructing a tile overlay system as recited in claim 16 wherein the tile surface is prepared by hand painting the tile surface to exhibit a distinct appearance.
 18. A method for constructing a tile overlay system as recited in claim 16 wherein the tile surface is prepared by fixing a photograph to the tile surface to exhibit a distinct appearance.
 19. A tile overlay system as recited in claim 15 wherein the tiles comprise a fabric backing disposed for contact with the liquid adhesive. 